Method and reactor for producing thermal energy and base chemicals

Abstract

The invention discloses a method for producing thermal energy and basic chemicals and a reactor used in the method. The reactor contains a reaction space for oxidizing the metal fuel with water or carbon dioxide and optionally other oxidizing agents. The reaction chamber is connected at its outlet to a separation device for separating solids contained in the product gas exiting the reaction chamber. A first flame is generated in the reaction space that triggers a reaction of the metallic fuel with the oxidant to generate a second flame in the reaction space. The first flame is generated by using a fuel mixture introduced into the reaction space via one or more feed lines. At the end of the feed line (s), an ignition device acts on the fuel to ignite a first flame, which in turn triggers the formation of a second flame. The thermal energy generated by the oxidation reaction is recovered by using one or more heat exchangers, which may be placed at different locations in the reactor. Using the reactor and process of the invention, hydrogen and / or carbon monoxide is produced from metal fuel and water or CO2. When water and carbon dioxide are used as oxidants, a mixture of hydrogen and carbon monoxide is produced. These products can be used as base chemicals in various processes.

Description

Technical Field

[0001] This invention relates to scalable metal-fuel concepts, to reactors designed for oxidizing metal fuels, and to optimized chemical conversions for simultaneously generating energy and basic chemicals for industrial applications. Background Technology

[0002] This invention relates to the growing interest in transporting and storing energy (especially renewable solar energy) and to integrating these process flows with the global demand for non-fossil or fossil chemical feedstocks, such as hydrogen, CO, and all products and commodities derived from them in all existing and future regional industrial sectors, including organic chemical compounds in which carbon is used as their most reduced form.

[0003] This invention addresses the need for raw materials, chemicals, and intermediates in a solar-driven circular economy with optimized energy volume density transport and efficient release.

[0004] In fact, industrial standards have even evolved to the global use of charcoal itself as a heat source or chemical feedstock in metallurgical processes implemented to date. These processes involve reducing minerals, particularly oxides, to produce specific metallographic phases such as steel or steel alloys, and reducing current using graphite electrodes in conventional aluminum smelting furnaces.

[0005] Relying on fossil carbon sources, whether natural gas, refined crude oil, or anthracite, various gasification and liquefaction processes have created interconnections between different production processes. Driven by global or regional energy prices, this interconnection has enabled the chemical industry to repeatedly switch its production processes since World War II, or when facing political sanctions or bailouts. As a result, even products such as hydrogen, food ingredients, and fertilizers are supplied through this technological and economic system, while more direct production methods, such as electro-fertilizers or hydrogen metallurgy, have been sidelined.

[0006] Therefore, to our knowledge, all product branches can be converted, transformed, or redirected to renewable energy, and most products can be produced with minimal or no carbon dioxide production, except for food or raw material metabolites produced by the metabolism of animals and mammals themselves. Since atmospheric dilution of carbon dioxide from this source is difficult or impossible to avoid, it is necessary to establish carbon dioxide itself as a source of carbon-based products (such as food or chemicals), as historical processes have shown that its carbon sequestration rate is too slow to handle the peak of 400 ppm in the air reached in a very short time.

[0007] The optimized reaction type in traditional industrial processes, which releases oxygen in the form of CO2 from aluminum electrolysis cells, precisely demonstrates the dual economic and technological advantages of using carbon in such basic material production reactions. Because carbon is a cheap thermal energy resource, the actual net combustion of graphite electrodes reduces the electrical energy required for activation and simple heating. This economic trade-off lies in the choice between grid costs and graphite electrode consumption. Using CO2 as exhaust gas and utilizing carbonaceous minerals is undoubtedly the most cost-effective option.

[0008] The concentration of carbon dioxide in the atmosphere will reach 400 ppm within the next few decades, and even if carbon dioxide emissions from human activities (including transportation, logistics, agriculture, consumer goods, and animal husbandry) are maintained or significantly reduced, the natural reduction of this level will take a long time. Therefore, all these industrial or civil processes that emit carbon dioxide into the atmosphere may become prohibited, and in terms of the environmental damage already caused, these processes are actually in a net loss.

[0009] Carbon capture and storage, as an end-of-pipe treatment solution, is not only costly and philanthropic in nature, but also fails to provide a preventative solution to the cyclical demand for these valuable materials and raw materials in a truly sustainable circular economy, a demand that will only continue to grow as "green" development progresses.

[0010] Furthermore, the urgent need to transport energy to generate or produce pure or technically-formed metals within a region reflects, from a thermodynamic perspective, the high enthalpy state of the metals themselves. Simultaneously, these metals, along with their mineral oxides, represent a high-volume-density chemical storage and release mechanism. In other words, hydrogen, as a gas, has the highest combustion energy mass density, and theoretically, the conversion of metals into their oxides achieves the highest practical enthalpy yield per unit volume.

[0011] Most technical industrial high-temperature flame processes, such as the production of glass, metals, or sintered materials, can be modified using the heat of a hydrogen flame or by using an electric arc to provide hydrogen reduction through the combustion of hydrogen in air or oxygen. Fortunately, this oxidation process, carried out in the form of a continuous flame, is a standard industrial high-temperature process because many such processes cannot be achieved by resistance heating.

[0012] This invention presents a novel optimization scheme to integrate all the above advantages and material flows: by establishing a safe and convenient transportation infrastructure (global metal / metal oxide cycle), high volumetric-time yield conversion of raw material metals is achieved, thereby generating electricity on demand, while utilizing the abundant H2O and CO2 fed back from the cycle to continuously produce hydrogen and standard carbon intermediates from basic chemicals and return them to the cycle.

[0013] Existing technology

[0014] The method of using metals as fuel conversion agents is well known.

[0015] WO 2014 / 173991A1 proposes a fully developed chemical-industrial multi-branch approach using aluminum as an energy storage material, which reacts with CO2 to generate heat energy for the thermal grid energy generation, while simultaneously converting CO2 into CO, which is used as a base chemical in chemical synthesis.

[0016] Metal burners that use air or oxygen without chemical conversion are well known.

[0017] The results of the aluminum-alumina cycle as a renewable energy storage method are reported in DIS-Vertrags Nr.: 150401 Programm Solarchemie / Wasserstoff; Bundesamt für Energie BFE Schlussbericht Juni 2004; Aluminium als Brennstoffund Speicher; J. Wochele, Dr. Chr. Ludwig; Paul Scherer Institut CH-5232Villigen. A key obstacle to the combustion of aluminum metal into its oxides in air or oxygen is disclosed. In this report, a flame reactor developed by an aluminum oxidizer is proposed and constructed. Most interestingly, the analysis points out that the greatest loss in such an energy cycle will be the carbon electrode itself, and therefore the industrial introduction of the now-established low-wear electrode will result in a reasonable energy storage-energy cycle itself.

[0018] Another working group, Trowell, focused on reacting aluminum in contact with water to release the enthalpy of the reaction as heat and hydrogen. The result is immediate access to clean power without the release of greenhouse gases. In a 2018 discussion, Trowell explained the basic reaction and potential applications of this technology concept. While laboratory work has shown that the use of metal fuels with heat engines is technically feasible, no one has yet demonstrated this conversion in practice. For example, BERGTHORSON, JM, et al. have published a concept: “Metal-Water Combustion for Clean Propulsion and Power Generation,” Applied Energy, vol. 186, January 1, 2017 (2017-01-01), pp. 13-27, XP055746514.

[0019] Therefore, the next step in translating laboratory findings into usable technology will be to establish a prototype conversion and couple it to a heat engine, again focusing on optimizing particle conversion at lower temperatures by proposing specialty metal powders including nanospheres; see https: / / www.mcgill.ca / newsroom / -channels / news / could-metal-particles-be-clean-fuel-future, published in 2015.

[0020] Professor Jeff Bergthson of McGill University plans to collaborate with Siemens Energy, Rio Tinto, Teck Resources Limited, Agnico Eagle Mines Limited, and Hydro-Quebec in structural engineering to develop alternative technologies for the continuous reaction of metals with high-pressure, high-temperature water to produce electricity, hydrogen, and / or heat.

[0021] F. Halter and Chauvau disclosed attempts to convert CO2 into a powerful flame, reporting low conversion rates, intermediate product yields, and droplet passivation even when using specially micronized aluminum in diluted transport gas devices.

[0022] Alexandre Braconnier et al. published an attempt to convert CO2 into a stable flame, reporting low conversion rates, intermediate product yields, and droplet passivation even when using specially micronized aluminum in diluted delivery gas systems (see Alexandre Braconnier, Stany Gallier, Fabien Halter, Christian Chauveau; Aluminum combustion in CO2-CO-N2 mixtures; Proceedings of the Combustion Institute, Elsevier, 2021, 38 (3), pp.4355-4363). The authors reported finding that aluminum burned in pure CO2 with a visible diffusion flame. In pure CO, they confirmed that the particles underwent weak combustion. Oxidation was maintained by a heterogeneous reaction without any envelope flame. It quickly ceased, presumably due to the formation of a passivation layer on the surface. Combustion in mixtures of CO2 and CO suggests that the almost inert behavior of CO and CO2 / N2 mixtures similarly gives rise to the overall inert behavior of N2.

[0023] None of the publicly available device designs and results indicate that those teams have overcome the scientific bias that only supercritical high-pressure steam equipment using specially micronized or even nanoscale aluminum allows for the production of clean hydrogen with significant thermal energy for industrial development.

[0024] Bergthrson points out that developing metal recycling methods that do not involve CO2 emissions is also crucial; see https: / / www.mcgill.ca / newsroom / channels / -news / could-metal-particles-be-clean-fuel-future-257172.

[0025] The inherently unknown pathway for the conversion of combustion from air or oxygen burners to molten aluminum and CO2 conversion is the lower inherent heat generated in the flame and the potentially lower or chemically diverted reaction, which inhibits yields, both energy-wise and chemically.

[0026] For continuous use, all academic or publicly available industrial methods typically only demonstrate a few aspects of the principles, obstacles, and optimizations of continuous metal-fuel combustion. Fewer technical or academic theoretical considerations demonstrate solutions for metal-fuel reactors in terms of bulk material usage and technically scalable processes.

[0027] Oxygen burners using specially micronized aluminum produce stable, continuous flames (F. Halter et al., Applications in Energy and Combustion Science, Vol. 13, https: / / doi.org / 10.1016 (2023)). Al, Mg, and alkali metals and their alloys have been reported to exhibit self-sustaining air-oxygen reactions from gas-propelled powder transport. The reported temperatures highlight the importance of self-sustaining dynamics within the flame geometry.

[0028] BERGTHHORSON, JM, in "Recyclable metal fuels for clean and compact zero-carbon power", Process in Energy and Combustion Science, vol. 68, September 1, 2018 (2018-09-01), pp. 169-196, XP55876570, discloses the use of metal fuels in internal combustion engines. The accompanying drawings disclose the combustion of metal powder with air in an Otto engine, which has an ignition spark and is equipped with an electromagnetic strip that allows the collection of oxidized metal particles from the exhaust gas. This concept does not disclose the introduction of water or carbon dioxide as an oxidant into the combustion chamber of the metal fuel, nor does it disclose the presence of a metallic primary fuel and a metallic auxiliary fuel in the combustion chamber.

[0029] Even fewer people have solved the problem of chemical transformation, especially the conversion of hydrogen from water or CO2 to CO.

[0030] WO 2021 / 228429A1 discloses the advantages of dispersing liquid metal fuels present in all Al smelting structures into a reactor along with precursor gases containing H2O or CO2, resulting in rational conversion and heat introduced into the system by liquid aluminum.

[0031] As mentioned above, although there are many scientific and theoretical hypotheses working on the reaction of Al with air, O2, and especially more importantly H2O and CO2, no technical burner or converter has yet been described as promoting a stable flame with continuous metered addition of solid Al (which does not clog) and using only micronized aluminum formulations in air or oxygen.

[0032] The Paul Scherer Institute in Switzerland has studied the use of Al as an energy storage material in small-scale burners and its oxidation in air to generate heat (compare J. Wochele, Chr. Ludwig; Aluminium als Brennstoffund Speicher. Bundesamt für Energie BFE (2004); https: / / infoscience.epfl.ch / record / 165265).

[0033] Although the oxidation of Al with oxygen-containing gases such as air is considered easier than that without oxygen, the burner becomes clogged even after several optimized steps. The difficulty of Al oxidation with CO2 or H2O is recognized in the review of combustion conditions (compare M. Beckstead; Correlating aluminum burning times. Combust. Explo. Shock Waves 41 (5) (2005) 533–546; https: / / doi.org / 10.1007 / s10573-005-0067-2).

[0034] Another parameter revealing the difficulty of oxidizing Al with oxidants H2O and CO2 compared to O2 is the time for particle combustion, which is inherently much longer in the case of H2O and CO2 (compare M. Beckstead; Correlating aluminum burning times; Combust. Explo. Shock Waves 41 (5) (2005) 533–54; https: / / doi.org / 10.1007 / -s10573-005-0067-2; or Alexandre Braconnier, Stany Gallier, Fabien Halter, Christian Chauveau; Aluminum combustion in CO2-CO-N2 mixtures; Proceedings of the Combustion Institute, Elsevier, 2021, 38 (3), pp.4355-4363; https: / / doi.org / 10.1016 / -j.proci.2020.06.028; or Dilip Srinivas). Sundaram, Puneesh Puri, Vigor Yang; A general theory of ignition and combustion of nano- and micron-sized aluminum particles; Combustion and Flame Volume 169, July 2016, Pages 94-109; https: / / doi.org / 10.1016 / j.combustflame.2016.04.005).

[0035] Furthermore, the adiabatic flame temperature indicates the difficulty of achieving stable technology transfer. As known from DS Sundaram UDC536.46 a, V. Yanga, and VE Zarkob; Combustion of Nano Aluminum Particles (Review), Combustion, Explosion, and Shock Waves, 2015, Vol. 51, No. 2, pp.173–196., DOI: 10.1134 / S0010508215020045, the adiabatic flame temperature is much lower, and therefore closer to the evaporation temperatures of Al with CO2 and H2O compared to O2 or air.

[0036] Furthermore, particle size influences the complete oxidation of aluminum materials. For example, Dilip Srinivas Sundaram, Puneesh Puri, Vigor Yang; A general theory of ignition and combustion of nano- and micron-sized aluminum particles. Combustion and Flame Volume 169, July 2016, Pages 94-109. https: / / doi.org / 10.1016 / j.combustflame.2016.04.005 reports that oxidation time increases significantly with particle size. Moreover, it is generally known that the higher volumetric surface area of ​​smaller particles supports mass transfer.

[0037] CN 10979584A reports the necessity of establishing special "combustible" particles in hydrogen production from water and Al cycles. This requires not only an atomization separation step with energy intake and dissipation losses, but also in-process control to ensure the quality of the water contact phase with proper micronized powder distribution. This is a technology far from being scalable on an industrial scale with practical time-volume yields. Furthermore, corrosion inhibitors are needed to ensure the rupture of the passivation shell surrounding any Al seeds or Al droplets during water vapor contact. In other words, CN 109795984A reiterates the technological bias of addressing the different problems arising from the low temperature and low enthalpy of the reaction compared to air and oxygen in the literature by adding a compartmentalized device solution, and implements a step-by-step approach. From this literature, the reaction conditions for integrating all the necessary materials to provide a self-sustaining flame phase cannot be obtained.

[0038] The object of the present invention is to provide a method for converting selected metals in an atmosphere that allows for a continuous flame, said atmosphere comprising H2O, H2O and CO2, H2O and NH3 or H2O, CO2 and NH3 and optionally an inert gas.

[0039] Another object of the present invention is a reactor designed to efficiently convert selected metals by providing a continuous flame in an atmosphere comprising H2O, H2O and CO2, H2O and NH3 or H2O, CO2 and NH3 and optionally an inert gas. Summary of the Invention

[0040] Surprisingly, these objectives can be achieved by heating a large quantity of combustible metal in a first step to melt or even evaporate at least a portion of the combustible metal. In this first step, a small ignition energy source, i.e., a first flame, is used to ignite a large quantity of combustible metal, thereby allowing the combustible metal to melt or even evaporate in the presence of H2O or an H2O-containing oxidant, and generating a second flame. The propagation of this second flame is maintained by continuously adding the large quantity of combustible metal and a continuous stream of H2O or an H2O-containing oxidant, thereby converting these into products in high yield and maintaining its own high enthalpy process as a second flame.

[0041] This invention relates to a method for generating heat energy and basic chemicals in a reactor having a reaction space, the reaction space having an inlet zone for reactants, a central zone, and an outlet zone for product gases, the method comprising at least the following measures:

[0042] a) Provide a metallic primary fuel selected from silicon, magnesium, iron, aluminum, or alloys containing these metals in the entrance zone of the reaction space.

[0043] b) Introduce H2O or CO2, or a mixture containing H2O, CO2 and / or NH3 or H2O, CO2, or the mixture diluted with an inert gas, into the inlet region of the reaction space.

[0044] c) Using one or more feed lines terminating in the inlet region, metallic auxiliary fuel particles and oxidant, or hydrogen and oxidant, or a mixture of two or more of the particles, hydrogen, and oxidant, are introduced into the inlet region, and the mixture of the particles and oxidant or the hydrogen and oxidant is generated at the ends of one or more of the feed lines.

[0045] d) Providing a first flame at the end of the feed line(s) by means of particles of metallic auxiliary fuel and oxidant or a mixture of hydrogen and oxidant, directing the first flame toward the metallic main fuel present in the inlet region.

[0046] e) By melting and / or evaporating a portion of the metallic main fuel, a reaction zone is created by the action of the first flame, thereby causing the metallic main fuel to react with H2O, CO2, or H2O, CO2, and / or NH3 to produce a second flame, yielding a product gas containing hydrogen and oxidized metal or carbon monoxide and oxidized metal or hydrogen, carbon monoxide and / or nitrogen and oxidized metal, and optionally (one or more) inert gases.

[0047] f) The product gas is discharged from the reaction space outlet area via an exhaust line and introduced into a solid separation device.

[0048] g) Separating solids from the product gas in a separation unit, thereby producing a purified product gas with no or reduced solid content.

[0049] h) The purified product gas is discharged from the separation unit, and

[0050] i) The heat generated in the reaction space, in the product gas and / or in the purified product gas is transferred to the heat transfer medium and used to generate electricity and / or for heating purposes.

[0051] In another embodiment, the present invention relates to a reactor for generating heat energy and basic chemicals, comprising at least the following elements:

[0052] A) A reaction space formed by a reactor jacket, the reactor jacket having an inlet zone for reactants, a central zone, and an outlet zone for product gases, having at least one feed line to the inlet zone for a metallic main fuel and at least one feed line to the inlet zone for H2O or CO2 or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases, or at least one feed line to the inlet zone for a mixture of metallic main fuel, H2O, or CO2 or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases, and at least one discharge line for product gases located in the outlet zone.

[0053] B) At least one separation device for separating solids from the product gas, connected to an exhaust line from the reaction space, and wherein purified product gas is generated.

[0054] C) At least one heat exchanger that transfers heat generated in the reaction space, in the product gas, and / or in the purified product gas to a heat transfer medium, said heat exchanger being connected to the reactor jacket and / or to an exhaust line from the reaction space to the separation device and / or to an exhaust line removing the purified product gas from the separation device, characterized in that...

[0055] D) At least one feed line for metallic auxiliary fuel particles, or for hydrogen, or for an oxidant, or for a mixture comprising at least two of said particles, hydrogen, and oxidant, wherein said feed line terminates in said inlet region and supplies said particles, hydrogen, oxidant, or a mixture thereof to generate said particles and oxidant or said hydrogen and oxidant mixture at the ends of said feed line for establishing a first flame, and

[0056] E) At least one ignition device ignites the mixture at the end of the feed line D) to generate a first flame at the end of one or more of the feed lines, thereby creating a reaction zone by transferring heat energy to the metallic main fuel present in the inlet zone of the reaction space to melt and / or evaporate a portion of the metallic main fuel, and igniting a second flame by initiating a reaction of the metallic main fuel with H2O or with a mixture containing H2O, CO2 and / or NH3. Detailed Implementation

[0057] This invention includes scalable methods and scalable reactors for generating kinetic heat for local or grid use and the essential base chemical gases hydrogen and carbon monoxide for decarbonization processes involving raw materials and commodities such as steel, syngas, synthetic fuels, food chain components, and chemicals. High conversion rates and continuous or quasi-continuous operation, along with rapid start-up and shutdown, are typical for large industrial reactors and furnaces. Weaker reaction enthalpy and slower initial reaction kinetics are effectively overcome by converging smaller flame zones, allowing for sustained reaction in a much larger conversion zone of the bulk metallic fuel to be melted and / or evaporated into a large, continuous visible radiative plasma zone, generating thermal power and continuous, non-clogging oxide particles of a size and density that are expelled from the reaction radiation space (flame space). In one embodiment, a standard reactor steel alloy is cooled by heat transfer and is robust against anticipated water vapor corrosion and hydrogen diffusion effects.

[0058] Standard methods in extended and gas separation can now be applied, leveraging the breakthroughs of this invention to achieve high yields and high durability. The toxicity of CO and the safety limits of hydrogen are known and well-managed in large industrial environments. In this economy, the fuel and the materials used in cyclical transportation are highly inert and stable and environmentally friendly. This technology can be applied in all regions of the world and in all economic systems, from small local facilities to large conglomerates and metropolitan areas.

[0059] The method of the present invention is preferably a continuous method. However, the method can also be operated intermittently.

[0060] The reactor and method of the present invention can be scaled up over a wide range. Typical scaling ranges are 10 kW to 10 GW, preferably 50 kW to 1 GW, of electrical energy generated by the heat produced by the method or reactor.

[0061] In step a) of the method of the present invention, a metallic main fuel selected from silicon, magnesium, iron, aluminum, or alloys containing these metals is introduced into the inlet region of the reactor chamber. In this application, silicon, as a quasi-metal, is designated as a metal.

[0062] In step b) of the method of the present invention, H2O or CO2, or a mixture containing H2O, CO2 and / or NH3, is introduced into the inlet region of the reactor chamber. This feed stream may optionally be diluted with an inert gas, such as nitrogen or argon.

[0063] Steps a) and b) can be performed separately. Therefore, the metallic main fuel and the feed stream containing H2O or CO2 can be introduced into the reactor chamber through separate feed lines. In an alternative embodiment, steps a) and b) can be performed in combination. Therefore, the metallic main fuel and the feed stream containing H2O or CO2 can be introduced into the reactor chamber as a mixture through one or more feed lines.

[0064] Metallic primary fuels can be used in the form of powder, pellets, strips, wires, ingots, or wires, preferably fed through a continuous or discontinuous reactor, optionally using a gas lock. Powdered metals or metal alloys are preferred.

[0065] The metals used in the method of this invention are silicon, magnesium, iron, or preferably aluminum. Alternatively, alloys containing two or more of these metals can be used. Examples of alloys are aluminum-magnesium alloys and silicon-aluminum alloys.

[0066] Metallic fuels can be prepared from corresponding oxides via melt electrolysis, preferably using electricity from renewable sources such as photovoltaic or wind power. Metallic fuels can also be used from metal waste, preferably in the form of aluminum waste.

[0067] Particularly preferred is the oxidation of the metallic main fuel in a flow-through reactor in a gas mixture having a main flow of H2O or CO2 or NH3 or H2O and CO2 or H2O and NH3 or H2O, CO2 and NH3. The oxidation of the metallic main fuel preferably occurs in the absence of oxygen. This essentially means that, without affecting the reaction, especially for small flames or preferably from an ignition device, the controlled addition of small amounts of oxygen, while not optimal, is still possible in principle. However, better results are obtained in the absence of oxygen. Therefore, particularly preferred is the oxidation of the metallic fuel in the absence of oxygen. Optionally, an inert gas may be present in the gas mixture to dilute the oxidant gas.

[0068] The metals or metal alloys used as metallic fuels in the methods of this invention can be obtained from industrial-scale metallic feedstocks and represent alternatives to other transportable energy sources. The metals or metal alloys are inert and harmless to storage and transportation. This gives these metals or metal alloys a significant advantage as energy sources over crude oil, natural gas, or coal, which are considered more environmentally harmful due to their development, refining, distribution, transportation, and downstream use.

[0069] The oxidant H2O can be obtained from known sources. Various types of water from a variety of sources can be used. Both fresh and brine water can be used. Fresh water is preferred. H2O can be added to the reactor in the form of steam or mist. Steam is preferred.

[0070] The oxidant CO2 can be obtained from atmospheric gases, from all kinds of combustion processes, or from other sources, and therefore can be removed from the atmosphere or industrial cycles. Thus, the advantage of the method of the present invention is that no CO2 is generated in the relevant energy production, but is actually consumed. The collected metal oxides are highly inert and do not cause any environmental pollution.

[0071] One or more of the reaction products, hydrogen or carbon monoxide, or both hydrogen and carbon monoxide, are hazardous gases. However, the extraction, treatment, and storage of hazardous gases have long been possible, particularly according to the processes currently used in the chemical industry, without any problems and in compliance with appropriate safety standards. The potential hazards of carbon monoxide and hydrogen are therefore comparable to those of other hazardous chemicals. One or more of the reaction products, hydrogen and / or carbon monoxide, can be advantageously used in many industrial processes. Hydrogen can be used in many reduction processes, such as the production of metals, such as iron, from metal oxides, or for the hydrogenation of organic compounds. Hydrogen can also be used as a fuel or source of heat energy. Mixtures of carbon monoxide and hydrogen can be used in many industrial processes to produce energy-rich hydrocarbon compounds, for example, for the production of fuels, such as kerosene. Increased use of the method of the present invention will provide carbon monoxide and / or hydrogen fuels for industrial purposes. Combustion of the hydrocarbons from the reaction products of carbon monoxide and hydrogen will again provide carbon dioxide, which can be fed back into the method according to the invention, or, when derived from the method, is at least CO2 footprint neutral. Therefore, the main advantage of the method of the present invention is that the energy generation can be universally, dispersedly and rapidly applied without causing additional CO2 environmental pollution, thereby allowing one or more reaction products, hydrogen or hydrogen and carbon monoxide, to be fed into the feedstock cycle.

[0072] Nitrogen, used as an inert feed gas for dilution and flame process control, does not cause the undesirable NOx problem in oxygen-enriched burners. This is a key quality and advantage of the high-temperature, low-oxygen method of the present invention, as metals have been shown to capture oxygen at these reaction kinetics and temperatures to facilitate this gas purification.

[0073] The reactant NH3 can also be obtained from known sources. NH3 can be used as a hydrogen source. The oxidation reaction (one or more) in the reactor generates a large amount of heat energy, thus maintaining high temperatures within the reactor chamber. This avoids the formation of nitrogen oxides as a byproduct from the decomposition of NH3.

[0074] In step c) of the method of the present invention, particles of metallic auxiliary fuel and an oxidant, or hydrogen and an oxidant, or a mixture of two or more of the particles, hydrogen and an oxidant, are introduced into the inlet zone of the reactor.

[0075] Particles of metallic auxiliary fuel and oxidant, or hydrogen and oxidant, can be introduced into the reactor inlet zone via separate feed lines. In an alternative and preferred embodiment, a mixture of particles of metallic auxiliary fuel and oxidant, or a mixture of hydrogen and oxidant, is introduced into the reactor inlet zone via one or more common feed lines.

[0076] One or more feed lines for auxiliary fuel and oxidant terminate within the reactor inlet zone, and the feed streams of auxiliary fuel and oxidant are oriented such that the individual feed streams of auxiliary fuel and oxidant mix at the ends of said one or more lines within the reactor inlet zone. This mixture of auxiliary fuel and oxidant is ignited by an ignition device to produce a first flame at the location of the auxiliary fuel-oxidant mixture.

[0077] In an alternative and preferred embodiment, the auxiliary fuel-oxidant mixture is generated outside the reactor and supplied to the reactor inlet zone via one or more feed lines.

[0078] At the end of one or more feed lines, in step d), the mixture of auxiliary fuel and oxidant is ignited by an ignition device to generate a first flame at the location of the auxiliary fuel-oxidant mixture.

[0079] As the metal used for auxiliary fuel, the same metal used for the main fuel can be used. Therefore, particles of silicon, magnesium, iron, and preferably aluminum, or particles of alloys of two or more of these metals, can be used.

[0080] Typically, the metallic particles used in step c) have a diameter of less than 100 μm, preferably less than 10 μm. The preferred diameter range for metallic particles is between 100 nm and 10 μm.

[0081] As an oxidant, oxygen, air, or oxygen-containing chemicals can be used in step c). Preferred oxidants are oxygen, air, H2O, and / or CO2.

[0082] Different ignition devices can be used to ignite a mixture of auxiliary fuel and oxidizer to produce a first flame. Ignition devices are known to those skilled in the art.

[0083] Examples of ignition devices are an electric arc arranged in the inlet area at the end of one or more feed lines, an induction heater arranged outside the reactor, or a laser whose radiation is coupled into the reactor chamber through one or more windows in the reactor jacket, or an induction heater that generates heat acting on the spatial region at the end of one or more feed lines to produce a first flame.

[0084] The first flame generated in step d) is used to generate the second flame in step e), which forms a reaction zone through the reaction of the metallic main fuel with H2O or CO2, or with H2O, CO2, and / or NH3. Thus, the first flame triggers the main reaction by igniting the metallic main fuel to react in an oxidation reaction. This results in a typically larger second flame.

[0085] To trigger the main reaction, a first flame must be directed toward the metallic main fuel present in the reactor inlet zone. Furthermore, the first flame generates a temperature within the metallic main fuel that melts at least a portion of it. This causes the metallic main fuel to react with H₂O, CO₂, or with H₂O, CO₂, and / or NH₃, and preferably generates a second flame from the at least partially gasified metallic fuel. The oxidation reaction of the metallic main fuel produces a product gas-particulate mixture containing hydrogen and oxidized metal, or carbon monoxide and oxidized metal, or hydrogen, carbon monoxide, and / or nitrogen and oxidized metal, depending on the oxidant used in the main reaction.

[0086] The temperature of the second flame can be controlled by process conditions. For example, the flow rate of the metallic main fuel and the oxidant containing H2O, CO2, or H2O through the reactor, the optional presence of an inert gas, or the continued presence of the first flame can affect the heat generated during the oxidation reaction.

[0087] The first flame is used to trigger the reaction between the metallic main fuel and the oxidant containing H2O and / or CO2. Therefore, step c) is only used to provide ignition for the metallic main fuel and can be terminated after the second flame has been established. Alternatively, step c) can continue after the ignition during the main reaction between the metallic main fuel and the oxidant containing H2O and / or CO2 to support the stability of the second flame even under turbulent conditions.

[0088] In a preferred embodiment of the method of the present invention, a first flame temperature of 2500-3500°C, preferably 2500-3000°C, is generated. This ensures the ignition of the metallic main fuel and the formation and spread of the second flame.

[0089] In a preferred embodiment, the second flame generates a temperature within the metallic main fuel at which at least a portion of the metallic main fuel evaporates. In this embodiment, process conditions are selected such that the second flame continues to evaporate a portion of the metallic main fuel. This can be achieved, for example, by controlling the flow rates of the metallic main fuel and oxidant or by using a selected molar ratio of metallic main fuel and oxidant in the reaction zone. Preferably, a temperature of 2000°C or higher is generated, more preferably 2000-3500°C, and most preferably 2500-3000°C. The temperature in the reaction zone is measured using a radiation thermometer.

[0090] A low proportion of oxygen may be present in the fuel stream of the second flame. The amount of oxygen in the feed gas stream is 5% by volume or less. However, it is preferable that there is no oxygen in the feed gas stream. The feed gas stream of the second flame is optimized to convert to hydrogen or CO, or hydrogen and CO. Although oxygen always helps to increase the enthalpy of the method, this results in a lower yield of the basic chemical products required per metal fuel.

[0091] In step e), a reaction zone is created by melting a portion of the metallic main fuel, under the action of a first flame, thereby causing the metallic main fuel to react with H2O or with CO2 or with H2O, CO2 and / or NH3 to generate a second flame, resulting in a product gas containing hydrogen and oxidized metals, or carbon monoxide and oxidized metals, or hydrogen, carbon monoxide and / or nitrogen and oxidized metals. Optionally, one or more inert gases are present in the product gas if one or more inert gases are introduced into the inlet zone of the reactor. Typically, the product gas consists of hydrogen and oxidized metals, or carbon monoxide and oxidized metals, or hydrogen, CO and oxidized metals, or hydrogen, N2 and oxidized metals, or hydrogen, CO, N2 and oxidized metals. In cases of incomplete reaction, the product gas may also contain small portions, such as up to 10% by volume, of H2O, CO2, NH3 and / or unreacted metallic fuel. Although the product gaseous components, hydrogen, N2, CO, H2O, CO2, NH3 and (one or more) inert gases, exist as gaseous product gaseous components, oxidized metals and metallic fuels exist as particulate solids.

[0092] In step f), the product gas is discharged from the reaction space outlet area through an exhaust line and introduced into a separation device for solids. One or more exhaust lines may exist, discharging into one or more separation devices. Preferably, a single exhaust line discharges into a single separation device.

[0093] Different separation devices can be used. These devices are known to those skilled in the art of flue gas purification.

[0094] Examples of separation devices are centrifugal separators, known as cyclone separators, or fabric filters, electrostatic filters, or ceramic filters. A preferred separation device is a cyclone separator.

[0095] Cyclone separators are used as mass force separators in technical equipment for separating solid or liquid particles contained in gases. Cyclone separators are used, for example, in flue gas purification. Centrifugal force, generated by creating eddies, is used for separation. In a cyclone separator, the product gas, carrying the particles to be separated, begins to rotate as it passes through a properly designed stationary separator at its own velocity. Solid particles are separated in the cyclone separator by their mass. The typical outer diameter of a cyclone separator ranges from 20 cm to 6 m. The product gas carrying the particles can be fed tangentially or axially into a rotationally symmetrical separator chamber. In both designs, the particles are conveyed to the walls of the separator chamber.

[0096] A tangential cyclone separator basically consists of four parts: an inlet cylinder (top), a cone (center), a particle collection container or hopper (bottom), and an insert tube (centrally located downwards from the top of the inlet cylinder). In the inlet cylinder, the product gas / particle mixture is injected tangentially and enters an annular path. Due to the conical shape of the subsequent cone, the rotational speed increases to such an extent that particles are thrown against the cone wall by centrifugal force and slowed to such an extent that they detach from the flow and enter the collection container. The purified product gas exits the cone upwards through the central insert tube. The guidance of the mixture can be enhanced by baffles attached in a spiral shape to the inner wall of the separator. To prevent eddies from tearing particles back from the hopper, the transition from the cone to the hopper is typically further closed by a top cone standing upright in the center, leaving only an annular slot between the cone wall and the top cone for particles to pass through into the hopper. The hopper can be emptied during operation via a rotary valve to prevent gas exchange with the environment.

[0097] In an axial separator, vortices are primarily generated by guide vanes. The immersion tube is located opposite the gas inlet. Separated particles enter the collection container through the annular gap between the separator wall and the immersion tube. Unlike tangential cyclone separators, the flow direction is not reversed in the case of an axial separator.

[0098] Since it is impractical to use correspondingly large cyclone separators for large product gas flows, several smaller cyclone separators connected in parallel are typically combined in a housing to form a multi-cyclone separator. Axial separators are commonly used for the operation of multi-cyclone separators. These can consist of up to several hundred individual separators.

[0099] In fabric filters, solid particles are separated from the product gas. The particles primarily accumulate on the outer surface of the filter media, forming a so-called filter cake, which itself acts as a highly efficient separator. Due to the filter cake, the pressure differential in the filtration system, and consequently, the energy consumption, continuously increases, making periodic regeneration necessary. This is typically achieved by introducing a pulse of gas against the flow direction, ensuring the filter cake is ejected. The discharged filter cake is usually removed from the filtration system's collection hopper via a rotary valve.

[0100] An example of a fabric filter is the bag filter. This is a type of surface filter in which the filter media forms a tube. Bag filters have long been used in gas cleaning and dust removal processes in many industrial processes as filtration separators. Bag filters consist of fibrous materials woven into tubes. In hot gas filtration, metal wire mesh is often used. The product gas containing solid particles is ideally fed into the filter bag in a cross-flow manner to avoid upward flow against the direction of particle settling. The product gas is guided above a distribution plate, where pre-separation occurs, and the product gas flow is equalized within the filter housing. The actual separation of particles occurs on the surface of the filter media or on the surface of the filter cake deposited thereon.

[0101] When using an electrofiltration unit, the product gas leaving the reactor is dusted. In electroparticle separation, solid particles become negatively charged in the gas stream with the aid of a spray electrode and deposit on the opposing deposition anode. A DC voltage of, for example, 30-80 kV is applied between the spray electrode and the deposition electrode. The resistivity of the charged particles is crucial for deposition. If it is too high, deposition will no longer occur. The separated solids are conveyed to a solids silo. The solids are discharged in dry form, or after pre-wetting with water, by means of a mixing screw.

[0102] In step g), solids contained in the product gas are removed in a separation device, thereby producing a purified product gas with no solid content or a reduced solid content. Preferably, at least 90% by weight, more preferably more than 99% by weight, of solids present in the product gas entering the separation device are removed by this device.

[0103] In step h), the purified product gas is discharged from the separation device.

[0104] In step i), the heat generated when the metal main fuel is oxidized is extracted and transferred to a heat transfer medium. This heat is used to generate electricity and / or for heating.

[0105] In step i), the thermal energy generated in the reaction space and contained in the product gas and / or purified product gas is transferred to the heat transfer medium. This is achieved by one or more heat exchangers connected to the reactor jacket and / or one or more heat exchangers connected to the discharge line between the reaction space outlet zone and the separation unit and / or one or more heat exchangers connected to the line that removes the purified product gas from the separation unit.

[0106] The heat transfer medium used in one or more heat exchangers is known to those skilled in the art. Examples of heat transfer media are water, glycols, glycerol, molten metal, molten salt, or hot oil, such as organosilicon or high-boiling-point hydrocarbons. Preferred heat transfer media are water, hot oil, or molten salt.

[0107] Thermal energy contained in a heat transfer medium can be supplied to an exploiting consumer. Exploiting consumers can be virtually any technological or chemical energy converter. Specifically, low-pressure or high-pressure steam turbines used for power generation, Stirling engines and other direct generators of heat engines or temperature gradients, and thermal decomposition reactors, particularly those used for the thermal decomposition of hydrothermal energy into hydrogen, can be referred to as exploiting consumers.

[0108] The hydrogen or hydrogen / carbon monoxide produced in the method of this invention is stored or fed into a chemical conversion process. The energy produced can be dissipated for energy conversion or heat or cold generation, such as for heating, by storing it or consuming it directly or indirectly. For example, the generated heat energy can be supplied to a low-pressure or preferably high-pressure steam turbine to generate electricity.

[0109] In one specific embodiment of the method and reactor of the present invention, a portion of the heat generated in the method is fed back to the reactants introduced into the reactor. This includes the feedback of partially reacted particulate mixtures. These measures result in a temperature rise to almost complete and rapid depletion of oxygen to avoid any products other than the expected metal oxide mineral particles and H2 or CO, or H2 and CO, which would otherwise become a source of stranded carbide mixtures. Furthermore, with N2 as the transport gas, a concentration of well below 100 mg / m³ is achieved. 3 The amount of harmful and toxic NOx is rarely obtained through the combustion of conventional high-temperature fuels.

[0110] In another preferred embodiment of the method and reactor of the present invention, the reaction rate is controlled not only by the entry of metal particles and their flow patterns (e.g., vortex rotation, concentric laminar flow, angular vertical or even converging controversial injection), but also by the mass flow of the metallic main fuel into the contact point of the temperature zone in contact with (one or more) the first flame.

[0111] In another embodiment of the method and reactor of the present invention, different metals are used to generate a highly atomized vapor metal main fuel zone for the reaction. Particulate metals, such as Mg, Si, Fe, Ti, Ca, Va, Ge, Ni, Mn, Zn, and Sn, can be used to generate a first flame to provide an overall two-stage gasification process through the interaction between the first and second flames. Preferably, Si, Mg, Fe, or Al is used to generate the first flame, with Al being the most preferred.

[0112] In a preferred embodiment of the method and reactor of the present invention, the same metal is used to generate the first and second flames. Al is most preferably used to generate the first and second flames.

[0113] The method and reactor of the present invention establish a controlled first oxidation reaction stage with a net negative enthalpy by generating a first flame. Furthermore, a second reaction stage with higher conversion and negative enthalpy is established in the same reactor, thereby providing a joined enthalpy for the heat of reaction.

[0114] Preferred methods or reactors use a first inlet and a second inlet to inject a particulate feed stream of metallic fuel, for example, by using a conveying gas or ballistic mass acceleration similar to a pump vortex or propeller. The first metallic fuel powder used to generate the first flame can have a particle size in the range of 1 to 500 μm, but particle sizes smaller than 1 μm are also possible. The second metallic fuel powder used to generate the second flame can have a much larger particle size, for example, in the range of 100 μm to 1 mm or larger. The heat from the first flame and a portion of the heat from the partially reacted particulate mixture will allow the second metallic fuel feed to be significantly micronized and gasified within the process to improve the conversion to a satisfactory steady-state flame process, which would not be achieved without in-process micronization via the heat of the first flame. Statistical thermodynamic considerations suggest that such a first flame center needs to be close to 2500, 2700, or above 3000 °C to generate a self-sustaining second flame region with the same temperature level.

[0115] This yield contrasts with conventional gas or petroleum fuel combustion, as strong oxygen concentrations can produce higher reactor temperatures, approaching those mentioned above. However, the adiabatic temperature is strongly limited by the onset of the dissociation of CO2 and H2O, products not produced in the method of this invention.

[0116] Surprisingly, the high temperatures generated in the method and reactor of this invention can be well managed and controlled, and introduced into the corresponding energy conversion heat exchangers of standard equipment. In industrial-scale applications, the size of the exchanger dome needs to be determined based on blackbody radiation, which is not a concern for large-scale equipment. This means that the high temperatures support heat transfer via radiation. Therefore, the heat exchanger no longer relies on highly turbulent airflow transport; instead, radiation is the guiding design principle for efficient fuel reactor flame pools, offering significant advantages in terms of expansion (size) and numbering (parallel reactors).

[0117] The metal oxides, such as alumina, obtained by the method of this invention possess optimal quality and contain trace amounts of metal. This allows for further recycling and the direct use of this high-quality product in furnace recycling, far superior to any mineral feedstock technically available for furnace metal production. This quality of solid phase, after separation from the gas by standard equipment such as cyclone separators or solid product ash traps, is typical of the product of the method of this invention. Otherwise, a product of this quality can only be obtained through multi-step, laborious, and expensive additional distillation.

[0118] A second flame is introduced into the reaction space via a carrier gas (typically a mixture of an inert support and an oxidant, such as steam / CO2), and the second flame is stabilized over a continuous time period. Preferably, the reaction is carried out in a heat and gas control system, allowing hot gases to be returned to the reactor's input zone and enabling the controlled utilization and separation of reaction products, including the heat energy generated during the reaction.

[0119] Advantageously, the generation of the first flame stage uses small-sized micronized metal powder to stabilize or ignite and modulate the second flame. The metal main fuel used for the second flame can have less granulation, higher size, or different qualities, such as in liquid form (liquid metal injection) or even solid form, such as rods, wires, or pellets.

[0120] In another preferred embodiment, the first flame is stabilized, controlled, and shaped by the rotation of the flow, for example by a vortex, or by using a mixing device.

[0121] The reactor of the present invention comprises a reaction space A formed by a reactor jacket. The reaction space includes an inlet zone, a central zone, and an outlet zone for product gases. The reactor has at least one feed line leading to the inlet zone for a metallic primary fuel and at least one feed line leading to the inlet zone for H2O or CO2, or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases, or at least one feed line leading to the inlet zone for a mixture of a metallic primary fuel, H2O, or CO2, or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases. The reactor has at least one discharge line for product gases generated in the reaction space, said discharge line being located in the outlet zone. A central zone exists between the inlet zone and the outlet zone, in which the reaction between the metallic fuel and the oxidant continues. Therefore, the reaction occurs in the inlet zone and the central zone, or a portion of the central zone.

[0122] The reactor shell is made of heat-resistant materials, such as high-melting-point metals like steel, molybdenum, or tungsten, or ceramics or refractory bricks. The shape of the reactor can vary considerably. The reactor can have various forms; for example, it can be a tube or a bundle of tubes. In an alternative embodiment, the reactor defines a reaction space of different shapes, such as a cuboid. In this embodiment, the reactor walls are lined with refractory bricks.

[0123] The reactor comprises two or more feed lines for discharging fuel into the inlet zone. For cylindrical reactors, these feed lines may enter the inlet zone axially or parallel to the cylinder axis and / or radially perpendicularly through the reactor jacket, or tangentially through the reactor jacket. Combinations of these line arrangements are possible.

[0124] The inlet zone can be part of the reaction space, which begins immediately after the circular end face of the cylindrical reactor. In another embodiment, the inlet zone can be conical and connected to one of the circular end faces of the cylindrical reactor jacket.

[0125] Fuel-based metallic fuel and oxidizer are introduced into the inlet area via feed lines. Fuel for the first flame is introduced into the inlet area via one or more feed lines (D). Fuel for the second flame is introduced into the inlet area via one or more feed lines. The metallic fuel may be introduced via one line, the oxidizer via another line, or a mixture of metallic fuel and oxidizer may be introduced via one or more feed lines.

[0126] One or more feed lines D) terminate in the inlet zone and introduce fuel for the first flame into that zone. At the end of this / these lines, an ignition device E) acts on the fuel and ignites the first flame. One or more first flames may be generated in the inlet zone. The first flame is used to initiate the main reaction to generate the second flame. In addition to igniting the second flame, the first flame may also be used to support the main reaction. In this embodiment, the first flame may continue to exist or may exist intermittently after the second flame is ignited.

[0127] Different ignition devices (E) can be used. Examples are as described above.

[0128] The reactor jacket may include windows for monitoring the reaction process in the reaction space and / or for providing laser radiation into the reactor space to ignite the first flame.

[0129] The reactor jacket is preferably equipped with a heat exchanger (C) to recover the heat energy generated during the reaction process in the reaction space.

[0130] The reactor includes one or more discharge lines for discharging product gases from the outlet zone to one or more separation units. The outlet zone is part of the reaction space and begins immediately before the product gas outlet of the reactor. In a cylindrical reactor, the outlet zone begins upstream of the circular end face. The discharge line can be one or more pipes or a conical hollow body that connects to the circular end face of the cylindrical reactor and to the separation unit.

[0131] The discharge line is preferably equipped with a heat exchanger (C) to recover heat energy from the product gas leaving the reactor.

[0132] Separation device B) is used to remove solid particles from the product gas. Different separation devices B) can be used. Examples are described above.

[0133] The purified product gas leaving the separation unit via an exhaust line can be fed to one or more heat exchangers to transfer the heat energy contained in the purified product gas to a heat transfer medium. Thereafter, the cooled product gas is fed into one or more storage containers or transferred to equipment for further processing. In an alternative embodiment, the hot purified product gas is fed directly to the equipment via an exhaust line for further processing.

[0134] Heat recovery can be achieved using conventional heat exchangers known to those skilled in the art.

[0135] In a preferred method of the present invention, the metallic fuel provided in step a) is introduced into the entrance region of the reaction space in the form of powder, fragments, pellets, ingots or metal rods.

[0136] In another preferred method of the present invention, the metallic fuel provided in step a) is an aluminum-magnesium alloy or preferably aluminum, and the oxidized metal produced in step e) is aluminum oxide.

[0137] In another preferred method of the present invention, the H2O introduced into the reaction space inlet region in step b) is in the form of water mist, or in particular water vapor.

[0138] In a preferred variant of this embodiment, water vapor or a mixture of water vapor and carbon dioxide or a mixture of water vapor and ammonia is introduced in step b), optionally with an inert gas, particularly nitrogen, to dilute the water vapor or mixture.

[0139] Another preferred method of the invention involves introducing metallic fuel and H2O or CO2 or a mixture containing H2O, CO2 and / or NH3 into the inlet region of a cylindrical reaction space via one or more axially and / or radially and / or tangentially extending pipes.

[0140] In a preferred variant of this embodiment, an inert gas and / or water vapor, or a mixture containing water vapor, carbon dioxide, and / or ammonia, is introduced into the inlet region of the reaction space via multiple tangentially extending pipes through the reactor jacket, resulting in the formation of vortices in the reaction space that move toward the outlet region.

[0141] In a preferred embodiment of the method of the present invention, the mixture introduced in step c) is a hydrogen-oxygen mixture, a hydrogen-air mixture, a hydrogen-chlorine mixture, an acetylene-air mixture, or a mixture of metal particles with a diameter of less than 100 μm and water vapor.

[0142] In another preferred embodiment of the method of the present invention, the first flame is ignited by using an ignition device, preferably by using an electric arc arranged in the inlet area, an induction heater arranged outside the reactor, or a laser, the radiation of which is coupled into the reactor chamber through one or more windows in the reactor jacket, such that the electric arc, the induction heater, and / or the laser radiation act on the mixture introduced in step c).

[0143] Preferably, the second flame in step e) generates a temperature above 2000°C through the reaction of metallic fuel with H2O or CO2 or with H2O, CO2 and / or NH3.

[0144] In a preferred variant of this implementation, the temperature generated in the second flame in step e) causes a portion of the metallic fuel to evaporate.

[0145] In another preferred embodiment of the method of the present invention, the product gas is introduced into one or more cyclone separators in step f).

[0146] In another preferred embodiment of the method of the present invention, the heat energy generated in the reaction space is transferred to the heat transfer medium flowing through a heat exchanger connected to the reactor jacket, and / or the heat energy of the product gas is transferred to the heat transfer medium flowing through a heat exchanger connected to the discharge pipeline between the reaction space outlet area and the separation device, and / or the heat energy of the purified product gas is transferred to the heat transfer medium flowing through a heat exchanger connected to a pipeline that removes the purified product gas from the separation device.

[0147] Preferably, the outer jacket of the reactor is cooled by a heat transfer medium, preferably by water.

[0148] In a preferred variant of this implementation, the heat transfer medium flowing through one or more heat exchangers is water, hot oil, or molten salt.

[0149] In another preferred embodiment of the method of the present invention, hot purified product gas is introduced into a heat exchanger located downstream of the separation unit to cool the purified product gas and to feed the heat energy contained in the purified product gas into the heat transfer medium. In an alternative embodiment, hot purified product gas is fed from the separation unit into a chemical reactor to reduce the hydrogen contained in the purified product gas or to react the mixture of hydrogen and carbon monoxide contained in the purified product gas.

[0150] The hydrogen, carbon monoxide, or hydrogen / carbon monoxide produced in the method of the present invention can undergo in-situ chemical reactions. For this purpose, various chemical reactions can be utilized, in which these basic materials can be refined (one or more). For example, hydrogen can be used in the hydrogenation or reduction reactions of organic compounds, such as in ammonia synthesis or in the production of iron from iron oxide. For example, carbon monoxide can react with water to form methanol. Preferably, carbon monoxide and hydrogen can be further processed into various organic compounds in a Fischer-Tropsch reaction.

[0151] Therefore, it is preferable to produce carbon monoxide and hydrogen together in the method of the present invention, and to further process these two basic materials directly in a Fischer-Tropsch reaction. The thermal energy extracted from the method of the present invention can be advantageously used in the method.

[0152] In order to provide a zero CO2 footprint method, which is a preferred method of the present invention, the metal used as the metallic fuel is prepared by metal oxide without producing CO2, preferably in a molten salt electrolysis apparatus without carbon electrodes.

[0153] The preferred reactor of the present invention is characterized by a reaction space, which is a volume surrounded by refractory bricks or the interior of a cylindrical jacket made of metal or ceramic.

[0154] In a preferred variant of this embodiment, the reactor comprises a cylindrical reaction space with an inlet region through which one to five axially extending feed lines, preferably two or three axially extending feed lines, and / or its inlet region through one or more radially extending feed lines passing through the outer reactor jacket, provided that at least one feed line is available for introducing a mixture of metallic primary fuel particles and oxidant or a mixture of hydrogen and oxidant.

[0155] In another preferred variant of this embodiment, the reactor comprises a cylindrical reactor jacket through which multiple feed lines pass tangentially to feed reactants into the inlet region.

[0156] In another preferred reactor of the invention, the ignition device is selected from one or more electric arcs arranged in the inlet area at the end of the feed line D) and / or one or more induction heaters or lasers arranged outside the reactor, the radiation of the laser being coupled into the reaction space through one or more windows in the reactor jacket, such that the electric arc and / or electromagnetic radiation and / or laser radiation act on the spatial region at the end of the feed line D) to generate a first flame.

[0157] In another preferred reactor of the invention, a cylindrical reaction jacket is provided, through which multiple feed lines pass tangentially to feed an inert gas and / or water vapor, CO2, or a mixture containing water vapor, carbon dioxide, and / or ammonia into the inlet zone, resulting in the formation of a vortex inside the reaction jacket that moves in the direction of the outlet zone.

[0158] In another preferred reactor of the invention, the separation device is one or more cyclone separators, preferably two or three cyclone separators.

[0159] In another preferred reactor of the invention, it comprises a heat exchanger connected to the reactor jacket and / or a heat exchanger comprising a discharge line connected to the outlet zone of the reaction space and the separation device and / or a heat exchanger comprising a discharge line connected to a discharge line for removing purified product gas from the separation device, or a discharge line for thermally purified product gas from the separation device, which is connected to a chemical reactor to reduce hydrogen contained in the purified product gas or to react a mixture of hydrogen and carbon monoxide contained in the purified product gas. Attached Figure Description

[0160] Figure 1 The reactor of the present invention is shown, having axially arranged feed lines for metallic fuel and oxidant.

[0161] Figure 2 The reactor of the present invention is shown, having axially and radially arranged feed lines for metallic fuel and oxidant. In this embodiment, the second flame forms a vortex around the first flame.

[0162] Figure 3 The reactor of the present invention is shown, having axially and radially arranged feed lines for metallic fuel and oxidant. In this embodiment, a first flame forms a vortex around a second flame.

[0163] Figures 1 to 3 The reactor shown is an improved implementation of the reactor disclosed by F. Halter et al. in their article Applications in Energy and Combustion Science, Vol. https: / / doi.org / 10.1016 (2023).

[0164] Figure 1 The reactor comprises a reaction space (1) having an inlet zone (2) for reactants and an outlet zone (3) for product gases. The inlet zone (2) comprises an axial feed pipe (4, 5) for a mixture of metallic fuel and oxidant for a first flame (8) and a second flame (9). An ignition device (6) is positioned near the end of the axial feed line (4). The ignition device (6) forms an electric arc and ignites the fuel supplied through the feed line (4), thereby producing the first flame (8). The first flame (8) in turn ignites the fuel supplied through the feed line (5), thereby producing the second flame (9). The reactor is formed by a cylindrical reactor jacket containing a window (10) for inspecting the reactions occurring inside the reactor. The reactor jacket is surrounded by a heat exchanger (12) having an inlet line (11a) and an outlet line (11b) for a heat transfer medium such as water. One front end of the cylindrical reactor jacket is sealed by a conical tail piece (7). Axial feed lines (4, 5) pass through the tail section (7). Another circular end face of the cylindrical reactor jacket connects to a conical discharge line (13) for the product gas, which connects the outlet zone (3) to a cyclone separator (14) for separating solid particles from the product gas. The purified product gas is fed from the cyclone separator (14) via line (15) to a heat exchanger (16) for extracting heat energy from the purified product gas into a heat transfer medium, such as water. The heat exchanger (16) has an inlet line (17a) and an outlet line (17b) for the heat transfer medium, and an outlet line (18) for cooling the product gas.

[0165] Figure 2The reactor comprises a reaction space (1) having an inlet zone (2) for reactants and an outlet zone (3) for product gases. The inlet zone (2) comprises an axial feed pipe (4) for a mixture of metallic fuel and oxidant for a first flame (8) and multiple radially or tangentially arranged feed lines (19) for a metallic main fuel or (one or more) oxidant or a mixture of metallic main fuel and (one or more) oxidant for a second flame (9). Due to the radial or tangential introduction of metallic main fuel and (one or more) oxidant, the second flame (9) forms a vortex around the first flame (8) and spreads along the direction of the outlet zone (3) in the vortex direction. An ignition device (6) is positioned near the end of the axial feed line (4). The ignition device (6) forms an electric arc and ignites the fuel conveyed through the feed line (4), thereby producing the first flame (8). The first flame (8) in turn ignites the fuel conveyed through the feed line (19), thereby producing the second flame (9). The reactor is formed by a cylindrical reactor jacket containing windows (10) for inspecting the reactions occurring inside the reactor. The reactor jacket is surrounded by a heat exchanger (12) with an inlet line (11a) and an outlet line (11b) for a heat transfer medium such as water. One front end of the cylindrical reactor jacket is sealed by a conical tail end piece (7). An axial feed line (4) passes through the tail end piece (7). The other circular end face of the cylindrical reactor jacket is connected to a conical discharge line (13) for the product gas, which connects the outlet area (3) to a cyclone separator (14) for separating solid particles from the product gas. The purified product gas is fed from the cyclone separator (14) via a line (15) to the heat exchanger (16) for extracting heat energy from the purified product gas to a heat transfer medium, such as water. The heat exchanger (16) has an inlet line (17a) and an outlet line (17b) for the heat transfer medium and an outlet line (18) for the product gas to be cooled.

[0166] Figure 3The reactor comprises a reaction space (1) having an inlet zone (2) for reactants and an outlet zone (3) for product gases. The inlet zone (2) comprises an axial feed pipe (4) for a mixture of a metallic main fuel and (one or more) oxidants for the second flame (9) and a plurality of radially or tangentially arranged feed lines (19) for a metallic fuel or (one or more) oxidants or a mixture of metallic fuel and (one or more) oxidants for the first flame (8). Due to the radial or tangential introduction of metallic fuel and (one or more) oxidants, the first flame (8) forms a vortex around the first flame (9) and spreads in the direction of the outlet zone (3). An ignition device (6) is positioned near the end of at least one of the radial or tangential feed lines (19). The ignition device (6) forms an electric arc and ignites the fuel conveyed through (one or more) feed lines (19), thereby producing the first flame (8). The first flame (8) in turn ignites the fuel conveyed through the feed line (4), thereby producing the second flame (9). The reactor is formed by a cylindrical reactor jacket containing windows (10) for inspecting the reactions occurring inside the reactor. The reactor jacket is surrounded by a heat exchanger (12) with an inlet line (11a) and an outlet line (11b) for a heat transfer medium such as water. One front end of the cylindrical reactor jacket is sealed by a conical tail end piece (7). An axial feed line (4) passes through the tail end piece (7). The other circular end face of the cylindrical reactor jacket is connected to a conical discharge line (13) for the product gas, which connects the outlet area (3) to a cyclone separator (14) for separating solid particles from the product gas. The purified product gas is fed from the cyclone separator (14) via a line (15) to the heat exchanger (16) for extracting heat energy from the purified product gas to a heat transfer medium, such as water. The heat exchanger (16) has an inlet line (17a) and an outlet line (17b) for the heat transfer medium and an outlet line (18) for the product gas to be cooled.

[0167] The following embodiments describe the present invention, but it is not intended to limit the invention to these embodiments.

[0168] Examples 1 and 2, considered as a whole

[0169] exist Figure 3 The reactor shown and designed for generating heat and valuable chemical products consists of the following main components:

[0170] - H2O, CO2 and aluminum injection

[0171] - Reactor chamber with an optical inlet for observing the flame

[0172] - Ignition device that generates the first flame

[0173] - (one or more) particle separation devices

[0174] - Heat exchanger.

[0175] The reactor chamber is surrounded by a 0.6-meter-long, 0.105-meter-diameter double-walled cooling tube.

[0176] Gaseous reaction products and oxide particles are driven to the tangential inlet of the first cyclone separator via a converging pipeline. A second cyclone separator improves the capture of solid oxides. The hot gas then flows to the secondary heat exchanger.

[0177] Metal fuel is supplied by Carl Roth with aluminum powder of greater than 99.8% purity.

[0178] Solid fuel injection is performed using the PALAS BEG 1000 Type B, which allows for continuous and uniform particle injection.

[0179] The gas temperature distribution in the reactor chamber is characterized by the use of a set of K-type thermocouples arranged along the axis of the chamber.

[0180] In addition, the particle temperatures in the first and second flames were measured using an IMPAC infrared ISR 12-LO dual-color pyrometer (λ1=800 nm, λ2=1050 nm).

[0181] Example 1

[0182] For the first flame: the initial reaction between pulverized Al (17 μm) and O2 reaches over 2000 °C. Once a stable flame is obtained, oxygen is gradually and completely replaced by vapor in a cyclone reactor using a tangential inert gas for dilution and dispersion. Dilution is only for safety and temperature control purposes for this particular experimental setup.

[0183] Once the first flame is stable, the second flame is ignited under the following conditions: an initial reaction between pulverized Al (5-20 μm) and additional vapor, reaching temperatures above 2000°C on the order of isostostoichiometry. The pulverized aluminum size is gradually increased to a maximum of 200 μm to demonstrate the versatility of the invention.

[0184] Output power between 2 and 25 kW was obtained at combined mass flow rates of pulverized aluminum from 0.1 to 1 g / s. At this stage of the experimental setup, the collected alumina showed satisfactory measurable conversion and yield. The trace amounts of unreacted aluminum could be readily explained by the initial ignition process.

[0185] Example 2

[0186] For the first flame: the initial reaction between pulverized Al (17 μm) and O2 reaches over 2000 °C. Once a stable flame is obtained, oxygen is gradually and completely replaced by CO2 in a cyclone reactor using a tangential inert gas for dilution and dispersion. Dilution is only for safety and temperature control purposes for this particular experimental setup.

[0187] Once the first flame stabilizes, the second flame is ignited under the following conditions: an initial reaction between pulverized Al (5-20 μm) and additional CO2, reaching temperatures exceeding 2000°C on the order of isostostoichiometry. The pulverized aluminum size is gradually increased to 200 μm to demonstrate the versatility of the invention.

[0188] Output power of 2–25 kW was obtained at combined mass flow rates of pulverized aluminum from 0.1 to 1 g / s. At this stage of the experimental setup, the collected alumina showed satisfactory measurable conversion and yield. The trace amounts of unreacted aluminum could be readily explained by the initial ignition process.

[0189] The flow rate of the injected oxidant is in the range of 4.6 Nm. 3 h -1 and 8.6 Nm 3 h -1 between.

[0190] Heat recovery is achieved using a water-cooled reactor chamber and a secondary heat exchanger.

[0191] The first flame is stabilized by a swirling flow generated by a fuel stream injected into the inlet region through four tangential inlets, such as... Figure 3 As shown. Swirl stabilization allows for high-power flame retention with small-sized oxidizers.

[0192] In one embodiment, the first flame is used to stabilize the second flame, wherein sufficient aluminum is atomized or vaporized to produce a self-sustaining, highly adiabatic flame state for complete reaction.

[0193] The fuel used for the second flame is gradually changed from an Al / O2 / N2 mixture to an Al / CO2 / N2 or an Al / H2O / N2 mixture. The initial conditions for one or more of the gases are: 5% CO2 / 95% N2 and 5% H2O / 95% N2.

[0194] The total flow rate of the second flame fuel can be maintained at 2.8 Nm. 3 The flow rate is approximately half that of the main flow rate. Under these conditions, CO2 and H2O react completely in the second flame, and the total flow rate exiting the reaction chamber is calculated to be 5.6 × 79 / 100 + 2.8 = 7.2 Nm³. 3 The total flow rate of H₂, CO, and H₂ is a maximum of 2.8 × 5 / 100 = 0.14 Nm.3 / h. The target output for CO and H2 volume fractions is 1.94%. Gradual increases in H2 and CO volume are possible in a continuous second flame. Particles obtained in the cyclone separator show the expected oxidation of the metallic fuel.

Claims

1. A method for generating heat energy and basic chemicals in a reactor, said reactor having a reaction space having an inlet zone for reactants, a central zone and an outlet zone for product gases, said method comprising at least the following measures: a) Provide a metallic primary fuel selected from silicon, magnesium, iron, aluminum, or alloys containing these metals in the entrance zone of the reaction space. b) Introduce H2O or CO2, or a mixture containing H2O, CO2 and / or NH3 or H2O, CO2, or the mixture diluted with an inert gas, into the inlet region of the reaction space. c) Using one or more feed lines terminating in the inlet region, metallic auxiliary fuel particles and oxidant, or hydrogen and oxidant, or a mixture of two or more of the particles, hydrogen, and oxidant, are introduced into the inlet region, and the mixture of the particles and oxidant or the mixture of the hydrogen and oxidant is generated at the ends of one or more of the feed lines. d) Providing a first flame at the end of the feed line(s) by means of oxidizing particles of metallic auxiliary fuel and an oxidant or a mixture of hydrogen and an oxidant, directing the first flame toward the metallic main fuel present in the inlet region. e) By melting and / or evaporating a portion of the metallic main fuel, a reaction zone is created by the action of the first flame, thereby causing the metallic main fuel to react with H2O, CO2, or H2O, CO2, and / or NH3 to produce a second flame, yielding a product gas containing hydrogen and oxidized metal or carbon monoxide and oxidized metal or hydrogen, carbon monoxide and / or nitrogen and oxidized metal, and optionally (one or more) inert gases. f) The product gas is discharged from the reaction space outlet area via an exhaust line and introduced into a solid separation device. g) Separating solids from the product gas in a separation unit, thereby producing a purified product gas with no or reduced solid content. h) The purified product gas is discharged from the separation unit, and i) The heat generated in the reaction space, in the product gas and / or in the purified product gas is transferred to the heat transfer medium and used to generate electricity and / or for heating purposes.

2. The method according to claim 1, characterized in that, The metallic primary fuel provided in step a) is introduced into the inlet region of the reaction space in the form of powder, fragments, pellets, ingots or metal rods.

3. The method according to claim 1 or 2, characterized in that, The metallic primary fuel provided in step a) is an aluminum-magnesium alloy or preferably aluminum.

4. The method according to at least one of claims 1-3, characterized in that, In step b), the H2O introduced into the inlet zone of the reaction space is in the form of water mist, or especially water vapor.

5. The method according to claim 4, characterized in that... In step b), water vapor or a mixture of water vapor and carbon dioxide or a mixture of water vapor and ammonia is introduced, optionally diluted with an inert gas, particularly nitrogen.

6. The method according to at least one of claims 1 to 5, characterized in that, The metallic primary fuel and H2O or CO2 or a mixture containing H2O, CO2 and / or NH3 are introduced into the inlet region of the cylindrical reaction space via one or more axially and / or radially and / or tangentially extending pipes.

7. The method according to claim 6, characterized in that, Inert gases and / or water vapor, or CO2, or a mixture containing water vapor, carbon dioxide, and / or ammonia, are introduced into the inlet region of the reaction space through multiple tangentially extending pipes through the reactor jacket, resulting in the formation of vortices in the reaction space that move toward the outlet region.

8. The method according to at least one of claims 1-7, characterized in that, The mixture introduced in step c) is a hydrogen-oxygen mixture, a hydrogen-air mixture, a hydrogen-chlorine mixture, an acetylene-air mixture, or a mixture of metal particles with a diameter of less than 100 μm and water vapor.

9. The method according to at least one of claims 1-8, characterized in that, By using an ignition device, preferably by using an electric arc arranged in the inlet area, an induction heater arranged outside the reactor, or a laser, the first flame is ignited, and its radiation is coupled into the reactor chamber through one or more windows in the reactor jacket, such that the electric arc, induction heater, and / or laser radiation act on the mixture introduced in step c).

10. The method according to at least one of claims 1 to 9, characterized in that, The second flame in step e) generates a temperature of 2500°C or higher through the reaction of the metallic main fuel with the H2O or with the H2O, CO2 and / or NH3.

11. The method according to at least one of claims 1-10, characterized in that, The temperature generated in the second flame in step e) causes a portion of the metallic main fuel to evaporate.

12. The method according to at least one of claims 1 to 11, characterized in that, The same metal, preferably aluminum, is used to generate both the first and second flames.

13. The method according to claim 3, characterized in that, The oxidized metal produced in step e) is aluminum oxide.

14. The method according to at least one of claims 1-13, characterized in that... In step f), the product gas is introduced into one or more cyclone separators.

15. The method according to at least one of claims 1-14, characterized in that, The heat generated in the reaction space is transferred to the heat transfer medium flowing through a heat exchanger connected to the reactor jacket, and / or the heat energy of the product gas is transferred to the heat transfer medium flowing through a heat exchanger connected to the discharge line between the reaction space outlet area and the separation unit, and / or the heat energy of the purified product gas is transferred to the heat transfer medium flowing through a heat exchanger connected to a line that removes the purified product gas from the separation unit.

16. The method according to claim 15, characterized in that, The heat transfer medium flowing through one or more of the heat exchangers is water, hot oil, or molten salt.

17. The method according to at least one of claims 1-16, characterized in that... The hot, purified product gas is introduced into a heat exchanger located downstream of the separation unit to cool the purified product gas, and the heat energy contained in the purified product gas is fed into a heat transfer medium, or the hot, purified product gas is fed from the separation unit into a chemical reactor to reduce the hydrogen contained in the purified product gas or to react the mixture of hydrogen and carbon monoxide contained in the purified product gas.

18. The method according to at least one of claims 1-17, characterized in that, The outer jacket of the reactor is cooled by a heat transfer medium, preferably water.

19. The method according to at least one of claims 1-18, characterized in that... The metal used as the primary or auxiliary metallic fuel is produced from metal oxides without generating CO2, preferably in a molten salt electrolysis device without carbon electrodes.

20. A reactor for generating heat energy and basic chemicals, comprising at least the following elements: A) A reaction space formed by a reactor jacket, the reactor jacket having an inlet zone for reactants, a central zone, and an outlet zone for product gases, having at least one feed line to the inlet zone for a metallic main fuel and at least one feed line to the inlet zone for H2O or CO2 or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases, or at least one feed line to the inlet zone for a mixture of metallic main fuel, H2O, or CO2 or for a mixture containing H2O, CO2, and / or NH3 and optionally (one or more) inert gases, and at least one discharge line for product gases located in the outlet zone. B) At least one separation device for solids from the product gas, connected to an exhaust line from the reaction space, and wherein purified product gas is generated. C) At least one heat exchanger that transfers heat generated in the reaction space, in the product gas, and / or in the purified product gas to a heat transfer medium, said heat exchanger being connected to the reactor jacket and / or to an exhaust line from the reaction space to the separation device and / or to an exhaust line removing the purified product gas from the separation device, characterized in that... D) At least one feed line for metallic auxiliary fuel particles, or for hydrogen, or for an oxidant, or for a mixture comprising at least two of said particles, hydrogen, and oxidant, wherein said feed line terminates in said inlet region and supplies said particles, hydrogen, oxidant, or a mixture thereof to generate said particles and oxidant or said hydrogen and oxidant mixture at the ends of said feed line for establishing a first flame, and E) At least one ignition device for igniting the mixture at the end of one or more of the feed lines D) to generate a first flame at the end of one or more of the feed lines, thereby generating a reaction zone by transferring heat energy to the metallic main fuel present in the inlet zone of the reaction space to melt and / or evaporate a portion of the metallic main fuel, and igniting a second flame by initiating a reaction of the metallic main fuel with H2O or with a mixture containing H2O, CO2 and / or NH3.

21. The reactor according to claim 20, characterized in that... The reaction space is a volume surrounded by refractory bricks, or preferably the interior of a cylindrical jacket made of metal or ceramic.

22. The reactor according to at least one of claims 20 to 21, characterized in that, It contains a cylindrical reaction space, with one to five axially extending feed lines, preferably two or three, in its inlet region, and / or one or more radially extending feed lines passing through the outer reactor jacket, provided that at least one feed line can be used to introduce metallic primary fuel particles, H2O, CO2, or a mixture of metallic primary fuel particles, H2O, CO2, and / or NH3, and at least one feed line can be used to introduce a mixture of metallic auxiliary fuel particles and oxidant, or a mixture of hydrogen and oxidant.

23. The reactor according to at least one of claims 20-22, characterized in that... It contains a cylindrical reaction jacket through which multiple feed lines pass tangentially to feed reactants into the inlet area.

24. The reactor according to at least one of claims 20-23, characterized in that... The ignition device is selected from one or more electric arcs arranged in the inlet area at the end of the feed line D) and / or one or more induction heaters or lasers arranged outside the reactor. The radiation of the laser is coupled into the reaction space through one or more windows in the reactor wall, so that the electric arc and / or electromagnetic radiation and / or laser radiation act on the spatial area at the end of the feed line D) to generate a first flame.

25. The reactor according to at least one of claims 20-24, characterized in that... A cylindrical reactor jacket is provided, through which multiple feed lines are tangentially fed into the inlet zone with an inert gas and / or water vapor, or CO2, or a mixture containing water vapor, carbon dioxide, and / or ammonia. As a result, a vortex is formed inside the reactor jacket, which moves toward the outlet zone.

26. The reactor according to at least one of claims 20-25, characterized in that... The separation device is one or more cyclone separators, preferably two or three cyclone separators.

27. The reactor according to at least one of claims 20-26, characterized in that, It includes a heat exchanger connected to the reactor jacket, and / or includes a heat exchanger connected to a discharge line between the reaction space outlet zone and the separation unit, and / or includes a heat exchanger connected to a discharge line for removing purified product gas from the separation unit, or includes a discharge line for discharging thermally purified product gas from the separation unit, the discharge line being connected to the equipment to reduce hydrogen contained in the purified product gas or to react a mixture of hydrogen and carbon monoxide contained in the purified product gas.

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